Abstract
A single mold Gasar process was developed to fabricate lotus-type porous copper with long and straight pores. The effects of withdrawing rate on the solidification front shape, pore morphology and average solid- ification rate of porous copper ingots were investigated through experimental study and Procast simulation. The re- sults show that the solidification front shape evolves from convex to planar, then to concave with increasing with- drawing rate. In this work, 1.0 mm/s is an appropriate rate for planar solidification front. In this case, all of the gas pores grow along the axial direction (parallel to the withdrawing direction) and the poresstraightness is the best. The average porosities of copper ingots are constant and independent of the withdrawing rate. But the average pore
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